Aseptic aerosol misting device

ABSTRACT

A handheld misting device includes a sonic generator, a power source coupled to the sonic generator, at least one reservoir containing a first liquid, and a conduit from the at least one reservoir. The sonic generator includes a converter and an elongate horn comprising a first horn section coupled to the converter and a second horn section physically connected to and removable from the first horn section. Sonic energy delivered to the first horn section is conducted to the second horn section. The conduit transports liquid from the at least one reservoir to the second horn section to a delivery opening distal the first horn section.

CROSS-REFERENCE TO RELATED APPLICATION

This is a divisional of U.S. non-provisional application Ser. No.15/337,365, filed Oct. 28, 2016, and claims the benefit of U.S.provisional application 62/248,699 filed Oct. 30, 2015. The completedisclosure of which is hereby incorporated herein by reference for allpurposes.

FIELD OF THE INVENTION

The present invention relates to an aseptic misting device employing apermanent sonic generator and a replaceable liquid reservoir and nozzle.

BACKGROUND OF THE INVENTION

Spray and/or misting devices are often used to delivery cosmetic andgeneral health care liquids. Low cost systems employ droppers and/orsqueeze bottles with some form of nozzle through which the liquid isforced to provide a relatively uncontrolled dosage and droplet size.

Expensive systems may employ metering pumps and/or expensive aerosolforming components. For example, Hseih et al. U.S. Pat. No. 7,992,800and Hseih et al. US Pub. Pat. Appn. No. 20120318260 disclose nebulizersdriven by piezo-electric and/or magnetic drives to generate an aerosolmist.

Other examples include The Technology Partnership PLC, EP615470B1;Hailes et al., U.S. Pat. No. 7,550,897; and Brown et al. U.S. Pat. No.7,976,135, which disclose liquid projection apparatus employingtransducers to project liquid droplets from an outer face of a nozzle.

Finally, Terada et al. U.S. Pat. No. 6,863,224; Yamamoto et al. U.S.Pat. No. 6,901,926; and Esaki et al. U.S. Pat. No. 8,286,629 discloseultrasonic liquid atomizing devices.

Unfortunately, these expensive components can be contaminated throughrepeated uses and require careful cleaning or disposal.

What is needed is a relatively low cost system for delivering controlleddoses and particle/droplet size aerosol mists.

SUMMARY OF THE INVENTION

Surprisingly, we have found that ultrasonically atomizing a liquidthrough a sonic generator including a two-part, elongate sonic horn,wherein the distal end of the horn is disposable and has at least onesubmillimeter-sized nozzle disposed at the end thereof providesinexpensive aseptic atomization by separating the liquid contained inthe reservoir from durable portions of the sonic generator.

In one embodiment, a handheld misting device includes a sonic generator,a power source coupled to the sonic generator, at least one reservoircontaining a first liquid, and a conduit from the at least onereservoir. The sonic generator includes a converter and an elongate horncomprising a first horn section coupled to the converter and a secondhorn section physically connected to and removable from the first hornsection. Sonic energy delivered to the first horn section is conductedto the second horn section. The conduit transports liquid from the atleast one reservoir to the second horn section to a delivery openingdistal the first horn section.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of a handheld aseptic misting deviceaccording to one embodiment of the invention.

FIG. 2 is a cross-section of the handheld aseptic misting device of FIG.1.

FIG. 3 is a side plan view of the sonic generator and liquid deliverysystem of the embodiment of FIG. 1.

FIG. 4 is a cross section of the liquid delivery section of theembodiment of FIG. 3.

FIG. 5 is a cross section of the liquid delivery section of analternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to a handheld sonic misting device that ismore economical than conventional sonic misting devices, because therelatively expensive sonic generator and horn are isolated from liquidsdispensed by the misting device. In one form of these devices, the hornis formed by physically coupling two sections together—a first sectionis permanently coupled to the sonic generator and a second, disposablesection is operatively connected to a liquid reservoir and is removablycoupleable to the first section. The liquid to be dispensed is deliveredfrom the second section at a location isolated from the first section,and the liquid dispensed from the device is directed away from the firstsection such that the first section is not contaminated by the liquidand subsequent liquids dispensed from the device are not contaminated bypreviously dispensed liquids. Examples of this system are shown below.

One embodiment of a handheld aseptic misting device is shown in FIG. 1.The handheld misting device 100 (including a sonic generator 200, aliquid delivery system 300, and an electric power and control system400) useful to form an aerosol comprising liquid droplets (referred toherein as a “mist” or “plume”) is contained within a housing 500. Thesonic generator 200 includes a converter 202 and an elongate horn 204having a first section 206 coupled to the converter 202 and a secondsection 208 physically connected to and removable from the first section206. The second section 208 has a first end 210 for connection to thefirst section 206 and a second, distal end 212, opposite the first end210. The second section 208 includes a delivery opening 214 disposed atthe distal end 212, an inlet port 216 disposed between the first anddistal ends 210, 212 and a conduit 218 disposed within the secondsection 208 between the inlet port 216 and the delivery opening 214. Thedistal end 212 extends from the housing 500. The converter 202 iscoupled to the electric power and control system 400 through electricalconnections, such as wires.

The liquid delivery system 300 includes a reservoir 302 with an outletport 304 and a conduit 306, in this embodiment, the conduit 306 is anannular space constrained by a pair of o-rings 308. The liquid isgravity fed to the outlet port 304. The conduit 306 conducts liquid fromthe reservoir 302 to the inlet port 216 of the second section 208 of theelongate horn 204. As indicated above, the liquid delivered to the inletport 216 can then be dispensed to the atmosphere from the deliveryopening 214.

The size, shape, and arrangement of delivery opening(s) 214 define theplume of mist generated by the misting device 100. The deliveryopening(s) 214 are dimensioned to deliver an aerosol mist. Preferably,each delivery opening has a maximum dimension (across the opening) ofless than about 200 microns (μm), more preferably, between about 50 andabout 150 μm. Preferred delivery openings are generally circular, butone of ordinary skill in the art may modify this to achieve specificallydesired aerosol properties. The number of delivery openings is selectedto deliver a desired misting flow.

In order to reduce the cost of operation of the handheld misting device100 of FIGS. 1-4, the housing 500 includes a first, electromechanicalsection 502 that houses components including the sonic generator 200(including the first horn section 206) and the electric power andcontrol system 400, and a second, liquid section 504 that houses thereservoir 302 and the second horn section 208. The liquid section 504can be securely attached to a reusable electromechanical section 502.

The electric power and control system 400 includes a power source, suchas a rechargeable battery 402, that is electrically connected to anelectrical charging port (not shown) disposed in the housing 500. Theelectric power and control system 400 also includes an on/off switch404, disposed on the housing 500, and one or more control boards 406.The power source is preferably replaceable and/or rechargeable and mayinclude devices such as a capacitor or, more preferably, a battery. In apresently preferred embodiment, the power source 402 is a rechargeablebattery including, without limitation, lithium-based cells, includinglithium polymer batteries. One example of an internal power source is alithium polymer cell providing a voltage of about 3.7 V that has acapacity of at least about 200 milliamp hours (mAh).

In greater detail as shown schematically in FIG. 3, the sonic generator200 and elongate horn 204 have a length λ. The sonic generator 200 andthe first section 206 of the elongate horn 204 combine to a length ofapproximately ½ λ, and the second section 208 also has a length ofapproximately ½ λ. The inlet port 216 of the second section 208 islocated approximately at the midpoint of its length. Thus, the inletport 216 of the second section 208 is approximately ¼ λ from the firstend 210 that is connected to the first section 206.

Although the liquid delivery system 300 described above includes areservoir 302 using a gravity liquid feed, one of ordinary skill in theart will recognize that other systems may be used. For example, theliquid delivery may be enhanced by including a pump or a reservoirpressurization system to force the liquid into the conduit.Alternatively, or in addition, one or more of the following may be used:pipette, syringe, collapsible reservoir, or squeezable bag.

An alternative embodiment of the liquid delivery system 300′ employingan alternative second horn section 208′ is shown in cross section inFIG. 5, and includes two separate reservoirs, 302 a and 302 b, eachhaving an outlet port 304 a and 304 b in liquid communication withrespective conduits 306 a and 306 b and second horn section conduits 218a and 218 b to deliver the liquids to delivery openings 214 a and 214 b.Each reservoir 302 a and 302 b may contain a separate liquid. The systemmay then be used to deliver one or the other liquids, by controlling thedelivery through the outlet ports 304 a and 304 b and ultimately thedelivery openings 214 a and 214 b, as indicated by arrows 220 a and 220b. Alternately, both liquids may be delivered simultaneously to thedelivery openings 214 a and 214 b to form a mixing plume formed of bothliquids. In this embodiment, the system can deliver liquids that must beseparated during storage.

The liquids dispensed from the device 100 may be aqueous and may includetherapeutic agents, reactants, proteins, and the like.

One of ordinary skill in the art will recognize the general assembly ofthe handheld sonic misting device of the present invention. However, theinteraction of the following elements is important to consider. Firstthe two horn sections should interlock securely to minimize energy lossdue to inefficient motion transfer therebetween to minimize heat buildupand to maximize control of the resulting aerosol plume. As the firsthorn section 206 is generally metallic, preferably aluminum and/ortitanium, the second horn section 208 should be made of the samematerials or, possibly of a compatible rigid plastic. For example in theembodiment of FIGS. 1-4, the second horn section 208 can be formed ofmetal or engineering plastic and machined or molded within appropriatetolerances to fit into the receptacle at the distal end of the elongatehorn. A non-limiting list of useful materials include acetal resins(such as available from DuPont® Engineering Polymers under the DELRIN®brand), polyether ether ketones, amorphous thermoplastic polyetherimide(PEI) resins (such as available from SABIC under the ULTEM® brand).

The reservoir may be formed of less expensive and/or more easily handledmaterials, such as polyolefins, polyesters, polystyrenes, and the like.

The housing may be fabricated by plastic injection molding, or any othersuitable technique, and it is preferably ergonomic and adapted to fitcomfortably in a hand of a user. In a preferred embodiment, the housinghas a maximum linear dimension (length) of up to about 20 cm, morepreferably, up to about 15 cm, and most preferably up to about 10 cm.Preferably, the maximum dimension perpendicular to the length is 8 cm,more preferably, 5 cm.

In a preferred embodiment, the liquid section 504 is removable from theelectromechanical section 502 in a manner in which the two horn sectionsinterlock securely.

The present invention is useful in the delivery of aerosol plumes ofmedication and/or moisturizing solutions in a more sanitary manner thancurrently provided. Sonic generation of aerosol plumes can provide veryfine mists, having a droplet size between about 20 and about 60 μm,given by the practical range of frequencies for the ultrasonic hornbetween 20 kHz and 200 kHz. As indicated above, as sonic generators aremore expensive than traditional squeeze and spray bottles, it isimportant to separate the expensive and reusable sonic generator andhorns from the relatively inexpensive and potentially disposable liquidreservoirs. Therefore, in use, a replaceable liquid section 502, can beslidably inserted into or threaded onto the electromechanical section504. Any protective covering (e.g., cap 506) can be removed from thedelivery opening(s) 214, and the misting device 100 can be energized.

To create an aerosol plume, the switch 404 is depressed, and the sonicgenerator 200 provides energy to the elongate horn 204. The liquid fromthe reservoir 302 is drawn into the conduit 306 and horn conduit 218 todeliver liquid to the delivery opening(s) 214. This sequence may berepeated until the reservoir is emptied. The now-empty liquid section504 can be removed and a new liquid section 504, including a new secondhorn section 208 and delivery opening(s) 214, is attached. The newsecond horn section 208 and delivery opening(s) 214 are not contaminatedas a result of the previous use of the misting device.

The specification and embodiments above are presented to aid in thecomplete and non-limiting understanding of the invention disclosedherein. Since many variations and embodiments of the invention can bemade without departing from its spirit and scope, the invention residesin the claims hereinafter appended.

What is claimed is:
 1. A handheld misting device comprising: a) a sonicgenerator comprising a converter and an elongate horn comprising a firsthorn section coupled to the converter and a second horn sectionphysically connected to and removable from the first horn sectionarranged and configured to form a single, linear elongate horn, wherebysonic energy delivered to the first horn section is conducted to thesecond horn section; b) a power source coupled to the sonic generator;c) a first reservoir containing a first liquid; d) a first conduithaving an inlet from the first reservoir to deliver the first liquidthrough the second horn section to a first delivery opening dimensionedto deliver an aerosol mist distal the first horn sections; e) a secondreservoir containing a second liquid, different than the first liquid;f) a second conduit having an inlet from the second reservoir to deliverthe second liquid through the second horn section to a second deliveryopening dimensioned to deliver an aerosol mist, proximate the firstdelivery opening; wherein each of the first and second conduit inletshas a central axis, each of the first and second delivery openings has acentral axis and the central axes of the inlets and delivery openings ofthe respective conduits are offset by an angle greater than zero degreesand wherein the second horn section has a length and the first andsecond conduit inlets are displaced along the length of the second hornsection and are separated by at least one seal.
 2. The handheld mistingdevice of claim 1 wherein the first and second reservoirs and secondhorn section are disposable.
 3. The handheld misting device of claim 1wherein at least one of the first and second liquids is aqueous.
 4. Thehandheld misting device of claim 1 wherein the first and second liquidscomprise reactants.
 5. The handheld misting device of claim 1 whereinthe first and second liquids comprise proteins.
 6. A handheld mistingdevice comprising: a) a sonic generator comprising a converter and anelongate horn consisting essentially of a single first horn sectioncoupled to the converter and a second horn section physically connectedto and removable from the first horn section arranged and configured toform a single, linear elongate horn, the second horn section comprisingat least a first and a second conduit, whereby sonic energy delivered tothe first horn section is conducted to the second horn section; b) apower source coupled to the sonic generator; c) a first reservoircontaining a first liquid operatively connected to an inlet of the firstconduit to deliver the first liquid through the second horn section to afirst delivery opening dimensioned to deliver an aerosol mist distal thefirst horn section; d) a second reservoir containing a second liquidoperatively connected to an inlet of the second conduit to deliver thesecond liquid through the second horn section to a second deliveryopening dimensioned to deliver an aerosol mist, proximate the firstdelivery opening; wherein each of the first and second conduit inletshas a central axis, each of the first and second delivery openings has acentral axis and the central axes of the inlets and delivery openings ofthe respective conduits are offset by an angle greater than zero degreesand wherein the second horn section has a length and the first andsecond conduit inlets are displaced along the length of the second hornsection and are separated by at least one seal.
 7. The handheld mistingdevice of claim 6 wherein the first and second reservoirs and secondhorn section are disposable.
 8. The handheld misting device of claim 6wherein at least one of the first and second liquids is aqueous.
 9. Thehandheld misting device of claim 6 wherein the first and second liquidscomprise reactants.
 10. The handheld misting device of claim 6 whereinthe first and second liquids comprise proteins.
 11. The handheld mistingdevice of claim 6 wherein the second liquid is different than the firstliquid.